High density high performance telecommunications/data link and connector with tap and contact displacement assembly

ABSTRACT

A telecommunications/data link and connector assembly is provided including a transmission cable comprising a plurality of transmission lines, a first interface end assembly and a second interface end assembly. The first interface end assembly comprises a first contact alignment body including a line connection end and an opposite end. A first end plurality of contact elements is provided with each of the contact elements being positioned and aligned by the first contact alignment body and extending from adjacent to the line connection end toward the opposite end. Each of the first side contact elements is movable between a contact position and a non-contact position. Each of the first side contact elements includes a contact area and a line connection area for an electrical connection with a line. A first end shield housing is provided wherein the first contact alignment body is disposed in the first end shield housing in a locked position. The contact alignment body may be removed from the first shield upon unlocking. The second interface end assembly has a second contact alignment body including a line connection end and an opposite end. A second end plurality of contact elements is provided with each of the contact elements being positioned and aligned by the second contact alignment body and extending from adjacent to the line connection end toward the opposite end. Each of the second side contact elements is movable between a contact position and a non-contact position, each of the second side contact elements including a contact area and a line connection area for an electrical connection with a line. A second end shield housing is provided wherein the second contact alignment body is disposed in the second end shield housing in a locked position.

FIELD OF THE INVENTION

The present invention relates to telephone systems and local areanetwork systems and more particularly, to an improved high densityconnector assembly for use within buildings for supplying a plurality ofwork areas with a selection of voice and data transmission links.

BACKGROUND OF THE INVENTION

Commercial space is often provided as open floor areas. These are oftendivided into work areas (cubicals). The occupant of the commercial spacetypically determines the most efficient use of the floor space for itsown needs and selects how the floor space is to be divided into smallerworking areas through the use of portable wall panels and similarstructures. So called “systems” furniture is used for dividing largefloor spaces into smaller work areas (cubicals).

Systems furniture arrangements typically utilize interior uprightspace-dividing panels which connect together, serially, through twopanel straight or angled connections, or through suitable three- orfour-panel connections to define a large plurality of individual workareas. Such panels are typically less than floor-to-ceiling height andcooperate with other furniture components to define an equipped workarea.

Each work area must be supplied with adequate electrical power andcommunication cabling. Various systems and components have beendeveloped including modular electrical systems which cooperate with andwhich readily mount on the panels. This allows the panels to bereconfigured and allows the supply of power to the work areas.

Systems have been proposed to avoid the use of a large number ofconventional four pair communication cables fed through floor conduitsor ceiling clearance spaces to the various work areas. Examples of suchprior art attempts include the systems and devices disclosed in U.S.Pat. Nos. 5,272,277; 5,160,276 and 4,928,303.

Numerous systems have been proposed relating to power lines and systemsfurniture. Many of these systems include features which solve particularproblems relating to power transmission and distribution with systemsfurniture.

U.S. Pat. No. 4,781,609 discloses a multicircuit electrical system whichis used with wall panels. The electrical system is a seven conductorsystem employing three live and three neutral conductors for definingthree separate electrical circuits each having a separate neutral. Aportable power tap unit (a receptacle unit) can be plugged into thepower block for selective engagement with any one of the three circuits.Although this system provides great advantages with regard to power andselecting one of the various circuits at the location, after the wallpanels are put into place, using the tap feature, the system involves agreat many components and is particular to the power distributionproblem.

U.S. Pat. No. 5,236,370 discloses another electrical system for use withinterior space dividing walls. The system is prefabricated and includeselongate harnesses mounted within channels which extend interiorly ofthe space-dividing members. Adjacent harnesses are electrically joinedby flexible electrical jumpers which create plug like connections withpower blocks. This system provides significant advantages as to ease ofuse. However, the system again includes numerous components which addssignificant expense. Additionally, the system again includes featureswhich are directed toward power distribution and problems associatedwith power distribution.

SUMMARY AND OBJECTS OF THE INVENTION

It is an object of the invention to provide a high density highperformance transmission and connector system for telecommunications anddata applications, wherein the connector provides a good physical andelectrical connection such that transmission portions can be linkedwhile maintaining high signal quality, even for high frequencyapplications and which system allows for a simple tapping of signals atthe connector.

According to the invention, a telecommunications/data link and connectorassembly is provided including a transmission cable comprising aplurality of transmission lines, a first interface end assembly and asecond interface end assembly. The first interface end assemblycomprises a first contact alignment body including a line connection endand an interface end. A first end plurality of contact elements isprovided with each of the contact elements positioned and aligned by thefirst contact alignment body and extending from adjacent to the lineconnection end toward the interface end. Each of the first side contactelements is movable between a contact position and a non-contactposition. Each of the first side contact elements includes a contactarea and a line connection area for an electrical connection with aline. A first end shield housing is provided wherein the first contactalignment body is disposed in the first end shield housing in a lockedposition. The second interface end assembly has a second contactalignment body including a line connection end and an interface end. Asecond end plurality of contact elements is provided with each of thecontact elements being positioned and aligned by the second contactalignment body and extending from adjacent to the line connection endtoward the interface end. Each of the second side contact elements ismovable between a contact position and a non-contact position, each ofthe second side contact elements including a contact area and a lineconnection area for an electrical connection with a line. A second endshield housing is provided wherein the second contact alignment body isdisposed in the second end shield housing in a locked position. Each ofthe first end shield and the second end shield is substantiallyidentical and matable. These end shields are also matable with a firstend shield and a second end shield of a substantially identicaltelecommunications/data link and connector assembly. Contact elementscarried by each the contact alignment body are in a contact positionwhen an associated end shield is in a mated position. A tap is providedwhich is insertable between contact elements for tapping signals carriedby the contact elements.

The tap includes a tap transmission line and connected contact portions.The tap contact portions make electrical contact with one of a firstside plurality of contacts and a second side plurality of contactselements.

A contact displacement means is provided for moving contacts between thecontact position and the non-contact position allowing insertion of thetap between the first side plurality of contact elements and the secondside plurality of contact elements. The contact displacement meansincludes a first contact opening device connected to the first sideplurality of contact elements. The first contact opening device isengaged by the tap means for moving contacts between the contactposition and the non-contact position allowing insertion of the tapbetween the first side plurality of contacts and the second sideplurality of contacts. The contact displacement means preferably alsoincludes a second contact opening device connected to the second sideplurality of contacts and a tip of the tap means. The first contactopening device and the second contact opening device are for movingcontacts between the contact position and the non-contact position.

The invention also includes a process of forming atelecommunications/data link and connector assembly including providinga contact alignment body with grooves for contacts and spaces forreceiving wire side contact ends. The contacts are positioned in thegrooves with wire contact ends extending into a wire and wire sidecontact end receiving spaces. A contact displacement member is providedconnected to ends of the contacts at the interface end. A wire guidewith a plurality of wire channels is also provided. The wire guide has acable end with a small width and a contact alignment body end with alarger width. The wire guide channels each have a wire path ofsubstantially identical length, extending from the cable side to thecontact alignment body side. A cable with wire terminal ends isemployed. These wire terminal ends are positioned in the guide channelsof the wire guide and a contact portion of the terminal ends extends outof the guide channels. The contact portions are electrically connectedwith corresponding contacts at wire side ends of the contacts. Thecable, the wire guide and the contact displacement assembly are joinedby applying an overlay molded housing. The overlay housing is applied bypositioning a portion of the cable, the wire guide and a portion of thecontact displacement assembly in a mold and injecting material in themold to form the overlay molded housing. The connected elements with theoverlay molded housing forms a single contact displacement assembly.

The wire contact ends and the contact wire side ends are preferablyelectrically connected by ultrasonic bonding (or ultrasonic welding).The contact alignment body preferably includes mold housing receivingsockets for receiving material of the overlay molded housing therein.The overlay molded housing preferably defines support rails.

A plurality of the single contact displacement assemblies are provided.These are inserted into a shield element forming a plurality of spaces.The shield element also includes a plurality of alignment portionscorresponding to each of the spaces. Two substantially identical shieldelements may be mated by connecting the alignment portions. Thealignment portions (alignment tabs) are preferably male and female in analternating arrangement, whereby two shields of substantially identicalform are mated by engaging the alignment portions while the shields arefacing and one is rotated 180° with respect to the other.

The shields are preferably formed of a plastic with embedded metallicelements. The metallic elements may be for example stainless steel. Thisprovides an important shielding function (shielding one mated contactset from adjacent mated contacts). This advantageously affects theperformance of the connector interface ends when they are mated with asubstantially identical interface end.

After inserting a contact alignment body of each single contactdisplacement assembly into each space of the shield, the contactalignment bodies are locked into place. When the shields are mated, thecontacts are engaged for passing electrical signals.

An indicator label element for a first side of the shield is providedand another indicator label element is provided for another side of theshield. Each indicator label element includes receiving grooves forreceiving a plurality of the support rails to cooperate with the singlecontact displacement assemblies and the shield to form a connectorblock.

The various features of novelty which characterize the invention arepointed out with particularity in the claims annexed to and forming apart of this disclosure. For a better understanding of the invention,its operating advantages and specific objects attained by its uses,reference is made to the accompanying drawings and descriptive matter inwhich a preferred embodiment of the invention is illustrated.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a perspective view showing a six circuit contact displacementassembly including two interface ends;

FIG. 2A is a left top perspective view of a shield element of thecontact displacement assembly of FIG. 1;

FIG. 2B is a right top perspective view of the shield element of FIG.2A;

FIG. 3A is an enlarged view of the detail A of FIG. 2A;

FIG. 3B is an enlarged view of the detail B of FIG. 2B;

FIG. 3C is an enlarged view of the detail C of FIG. 2A;

FIG. 4 is a cross sectional view of two shield elements in a positionoriented for mating, with the tongue element shown in phantom in thelocked mating position;

FIG. 5 is an exploded view of an interface end with the tap shown in aposition for engagement;

FIG. 6 is a perspective view of interface ends of a single contactdisplacement assembly (CDA), a component of the six circuit CDA of FIG.1;

FIG. 7A is a cross-sectional view of an interface end of the single CDAassembly of FIG. 4;

FIG. 7B is a top view of a cable with twisted pair wires passing througha wire guide and connecting to contacts of the contact alignment body ofan interface end;

FIG. 8 is a perspective view of the wire guide;

FIG. 9A is a perspective view of the contact alignment body withcontacts attached to a lead frame and connected contact displacementdevice being inserted therein, prior to connection with the wires andwire guide;

FIG. 9B is a perspective view of the contact alignment body withcontacts attached to a lead frame inserted therein, prior to connectionwith the wires and wire guide;

FIG. 9C is a cross sectional view showing the contact alignment bodyprior to insertion of the contacts;

FIG. 9D is a bottom front perspective view showing the contact alignmentbody before being associated with the contacts and contact displacementdevice;

FIG. 10A is a cutaway view showing a portion of the cable and twistedpair terminal ends;

FIG. 10B is a cross-sectional view of the cable;

FIG. 11 is a interior side front perspective view of the color indicatorlabel of the six circuit contact displacement assembly of FIG. 1;

FIG. 12 is an interior side front perspective view of the circuitindication label support element of the six circuit contact displacementassembly of FIG. 1;

FIG. 13A is a left top perspective view of the tap according to theinvention;

FIG. 13B is a right bottom perspective view of the tap according to theinvention;

FIG. 13C is a front view of the main tap element, prior to the main tapelement being connected with lines of a cable being joined with a tapmolded portion;

FIG. 14 is a partial side cutaway view illustrating contact betweencontacts of mated interfaces; and

FIG. 15 is a side sectional view showing a mated interface with aninserted tap wherein a line is tapped and a downstream line isdisconnected.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the drawings in particular, the invention comprises amulti-circuit contact displacement assembly (CDA) generally designated10. The assembly includes a fist interface end assembly 6 and anidentical (substantially identical, apart from minor tolerancevariations) second interface end assembly 8. Although the interface ends6 and 8 are identical, they have male and female portions (alignmenttabs) whereby they are adapted to be positioned in a mated contactstate. Each interface end 6, 8 is intended to be used for matingconnection with another multi-circuit CDA to provide a linking oftransmission lines at the contact interfaces and to provide a tappingregion for tapping the lines. The multi-circuit contact displacementassembly 10 is particularly useful when disposed in modular officefurniture components such as modular walls used to make office cubicals.A plurality of contact circuit assemblies may be provided in parallel(such as three) for eighteen different single contact displacementassemblies in parallel providing a multiplicity of two pair lines.

FIG. 1 shows a six circuit CDA 10 with each interface end (6, 8) havinga shield 12 supporting a plurality of contact alignment bodies 14. Asdiscussed further below, the contact alignment bodies 14 may be snappedinto shield 12 where they are retained for providing one connection sideat a contact interface. The contact alignment bodies 14 are part ofsingle contact displacement alignment (CDA) assemblies 18. In theposition as shown in FIG. 1, with the single CDAs 18 supported by shield12, color indicator label element 16 may be connected to the single CDAassemblies 18. Additionally, a circuit indicator element 20 may beconnected to the single CDA assemblies 18 on a non-tap insertion side ofeach interface. On a tap side of the interface, the single CDAassemblies 18 are exposed.

FIG. 2A shows a left top perspective view of a housing, particularly ashield housing 12. The shield housing 12 is preferably a unitary moldedstructure. The shield housing 12 is preferably formed of a plastic withembedded stainless steel fibers or stainless steel elements to providean electrical shield function. The shield 12 has an upper surface 26, atap access side 28, a non-access side 30 as well as a bottom 32 (seeFIG. 1). The bottom 32 includes a tongue 34 which provides an engagementfunction for connection of two interface ends. The tongue includes atongue bezel 36. To provide for engagement, each shield includes a maleenclosure portion 38 and a female enclosure portion 40 (these are alsoreferred to as alignment tabs). These two enclosure portions mate forconnection of two interface ends. The tongue bezel 36 provides for easeof insertion of the tongue 34 between an upper surface of male enclosureportion 38 and an interior surface of upper portion 26. On the undersideor bottom side 32, the tongue includes an engagement bezel 42 with alocking rear edge. This allows a locking of one interface side byengagement of the engagement bezel 42 with the back edge of upperportion 26 as shown in phantom line in FIG. 4. The ramp 44 assists inlocking the assemblies by providing a friction surface. The stop portion46 provides a stop function upon contact of the front edge of stopportion 46 with a front edge of the shield upper part 26. Interfacesides of single CDA assemblies 18 are connected to each other via singleCDA assembly cable 22.

FIGS. 3A, 3B and 3C provide enlarged views of the shield 12. As seen inFIG. 3A, at the access side 28 tap entry portion 50 delimits an upperedge of one side of a tap slot 56 which will be defined by matedinterface ends. At the tap side 28, the male enclosure portion 38includes a female recess 52 and a male portion 54. Male portion 54 istapered to allow ease of connection of the two parts for mating contact.As can be seen from FIG. 3B, just behind each enclosure portion (bothmale enclosure portion 38 and female enclosure portion 40), the shield12 has locking slots 57. These slots 57 are used for fixing the singleCDA assemblies 18 to the shield 12. The shield 12 is shown in a positionoriented for mating with another shield 12 in FIG. 4.

FIG. 6 shows a single contact assembly 18 including a single interfaceelement end and portions of the associated cable 22. Each interface endof the assembly 18 includes an overlay molded housing 58. This overlaymolded housing 58 has a function of joining the various components ofeach interface end of assembly 18. The overlay molded housing 58includes support rails 60. These are discussed further below. Eachassembly 18 also includes a contact alignment body 14 with contacts 62and contact opening device 66. Each interface end of the assembly 18also includes a wire guide 64 (see FIGS. 7A, 7B and FIG. 8).

FIG. 7A shows a cross-sectional view of an interface end of assembly 18,taken just above the contact surface. It can be seen that the overlaymolded housing 58 extends into a region of the contact alignment body 14to connect overlay molded housing 58 and alignment body 14. In joiningwith the body 40, overlay molded housing 58 also houses and surroundswire guide 64. Overlay molded housing 58 also extends into the channels88 which are provided for twisted pair terminal ends 110. This isdiscussed further below.

FIG. 7B shows a cable 22 with twisted pair terminal ends 110 extendinginto wire guide 64. The twisted pair terminal ends 110 also extend intocontact alignment bodies 14 where they are connected (and make contact)with contact 62. The structure shown in FIG. 7B is the single CDAassembly 18 just prior to the application of the overlay molded housing58.

FIG. 8 shows the wire guide 64 with a variety of channels 63. Thesechannels 63 are significant as they provide twisted pair channels whichare of substantially identical length (from one end to an opposite end).In this way, twisted pair wires 110, as shown in FIG. 10 can be usedwhich have terminating ends which are of substantially the same lengthfor each twisted pair 110. This provides a significant advantage as tomanufacturing. Wire guide body 64 includes alignment protuberances 92which facilitate alignment of the wire guide body 64 and the contactalignment body 14 during manufacture. Wire guide body 64 also includesoverhang portions 64 which help retain the twisted pair within thechannels 63 of wire guide body 64.

FIG. 9B shows the contact alignment body 14 with associated contactelements 62 still connected to a lead frame 73 (the lead frame issubsequently removed) and contact displacement device (or contactdisplacement device) 66. As can be seen in FIG. 9A, the contact openingdevice 66 has a tap cam follower 68 with locking protuberances (orposts) 70 for locking in the contact position. The cam follower 68includes bezel ramp 72 which allows insertion of the tap 138 and beginsmovement of the contact opening device 66 for moving contact portion 76out of engagement as a tap 138 is inserted between contacts of matedinterfaces. Each contact element 62 includes a spring portion with bend74 and barbs 78.

As can be seen in FIGS. 9A and 9D, each contact alignment body 14 has afront end with a receiving region 79 and a similar tap side receivingregion 79′. These have at their very front edge a engagement bezel 80.As can be seen from FIGS. 9A and 9D, each bezel 80 is on an upper andlower side of each alignment body 14. At an upper side of each contactalignment body 14 there is provided a stop edge element 82. At the backside of contact alignment body 14 there are wire openings 88 as well asalignment slots 90 (see FIG. 9A).

FIG. 9D shows the underside of the contact alignment body 14. Thisincludes a molded housing receiving space 96. By viewing FIGS. 9D and9A, it can be appreciated that the overlap molded housing 58 extends upto the rear side of stop edge 82, extends into molded housing receivingsockets 86 and into molded housing receiving space 96, thereby unifyingthe contact alignment body 14, the wire guide 64 and the electricallyconnected contacts and twisted pair terminal ends. This assemblytechnique has the further advantage that the overlay molded housing 58(see FIGS. 6, 7A and 7B), surrounds the cable jacket 112, surrounds thetwisted pair terminal ends 110 and extends into the terminal end panelsof wire guide 64. Overlay molded housing 58 also surrounds a rearportion of contact alignment body 14 and extends into the molded housingreceiving sockets 86, surrounds the wire contact interface engages thecontact barbs 78 and also fills the molded housing receiving space 96.This results in, among other things, a joining of the cable jacket 112and the contact alignment body 14 such that there is no strain of theindividual twisted pair terminating ends 110 and there is no strain atthe contact interface between twisted pair terminating ends 110 andcontact elements 62.

An alternative embodiment of the invention may also be provided whereinno wire guide 64 is provided. In this case the pair of terminating ends110 are welded or otherwise electrically connected and affixed tocontact elements 62 and the overlay molded housing 58 is applied. Theoverlay molded housing 58 provides isolation of the twisted pairs 110.The alignment slots 90 are not required.

FIG. 9C shows a cross-sectional view of the contact alignment body 14.In this view the receiving region 79′ is shown along with the engagementbezel 80. Further, an alignment region 87 is shown which includes wallsand a base support for positioning a contact element 62. Underneath andbehind the stop 82 there is provided a space 89 which communicates withthe mold housing receiving socket 86 and also communicates with the wireopenings 88. This space 89 receives the wire side end of contact element62. Although space 89 communicates with opening 86 and wire opening 88,the upper side regions of space 89 are delimited by the plastic (orother suitable material) walls of contact alignment body 14 such thatupon insertion of the wire ends of contact elements 62 into space 89,the barbs 78 engage the contact alignment body housing 14. The contactelement 62 cannot be effectively or easily removed from the contactalignment body 14, once they are inserted into the space 89, as thebarbs 78 will dig into the plastic contact alignment body housing 14above space 89, upon a pulling of the contact element 62 in a removaldirection. Specifically, the barbs 78 are angled such that insertion ofthe wire end into the space 89 is fairly smooth but any retraction ofthe contact element 62 is effectively prevented as the barbs 78 engagethe material of the alignment body 14 delimiting parts of space 89.

FIGS. 10a and 10 b show aspects of the cable 22 for single CDA assembly18. The cable 72 includes the cable jacket 112 and the twisted pairterminating ends 110. FIG. 10b shows the relative position of thevarious twisted pairs 110 and the jacket 112.

FIG. 11 shows the interior side of a color indicator label element 16.Element 16 includes a rail receiving portion 116 for receiving ends ofrails 60 of an interface end of CDA 10. Each rail 60 is from one singleCDA assembly 18. The rail receiving portion 116 includes a narrow ridgesuch that element 16 slides on the various rails 60 of the variousassemblies 18. Locking protuberances 122 cooperate with the lockinggroove 124 formed in overlay molded housing 58 of each interface end ofeach assembly 18 (see FIG. 7A). Another locking groove 136 is alsoprovided in each rail 60 of each molded housing 58. Locking protuberance122 allows the color indicator label element 16 to slide on the rails 60of the assemblies 18 and be locked into position.

FIG. 12 shows a circuit indicator 20, which is connected to a pluralityof assemblies 18 at one interface end, on a side opposite to an accessside. The rails 60 on the access side are used for fixing the tapelement 138 as described below. Circuit indicator 20 includes a railreceiving groove 126 with a base. The groove also defines a smalldimension gap which allows the groove to be attached by sliding element20 on to the rail 60 (or snapping it on). A protuberance 128 extendsoutwardly from the groove base and provides a locking element forextending into locking groove 136 of molded housing 58.

FIGS. 13A and 13B show views of a tap assembly 138. Several tapassemblies may be used with each mated interface. Each tap 138 is usedto tap lines at an interface of contacts of single CDA assemblies 18 ofmated interface ends of two CDA assemblies 10.

Each tap assembly 138 includes a body 140 with grasping region. A tapline 142 extends into the body wherein the various wires of tap cable142 are connected to traces provided in or on a tap slot insertionelement 150. The traces extend to contacts 148. A plurality of contacts148 are provided on a contact side 152 of the tap slot insertion element150. The tap body 140 is provided with a rail engagement portion 144.This defines a rail receiving groove 146 for rail 60. With thisstructure, the tap assembly 138 may be engaged with mated interface endsand fixed at exposed rail 60 on the tap side of one interface body suchas interface body 8 (see FIG. 1).

As can be seen in FIG. 14, when interface ends are mated, the contactsare in an electrical contacts position with the contact portions 76 inphysical contact for providing an electrical connection. As can be seenby comparing FIGS. 3A to FIGS. 3B, each tap slot insertion element 150includes a contact side 152 and an opposite side 154. When the tap slotinsertion element 150 is inserted into the insertion slot 56 (see FIG. 1and FIG. 3A), the tap is positioned for connection of rail engagementportion 144 with the exposed rails 60 of the assemblies 18, the contacts148 will connect with contacts 62 at the upstream side of thetransmission line (see FIG. 5). The down stream side of the transmissionline is broken as the contact 62 on the inner side of the interface (inthe upstream interface element) is maintained out of contact with thetap due to the camming surfaces of tap cam follower 68 (protuberances70, and the surface of tap opposite side 154). This state is shown inFIG. 15. A more detailed discussion of a similar contact displacementarrangement is discussed in U.S. patent application Ser. No. 08/651,414(filed May 22, 1996), which is hereby incorporated by reference.

The protuberances or posts 70 in the contact opening device 66 are suchthat the contacts 62 are maintained in a non-contact position while theinsertion element 150 is inserted between the contacts. When the tap 138is properly positioned, the posts or protuberances 70 extend intoopenings 153. It is possible to only have openings 153 on the contactside 152 and to not have these on the opposite side 154. This willmaintain one set of contacts 62 in a non-contact position. However, asno contacts 148 are provided on side 154, holes 153 can be provided onside 154 as well. This allows the contacts to move into a contactposition although no electrical contact is made and the down stream lineis disconnected.

The dimension of the tap slot insertion element 150 and the tap slots 56defined by engaged parts of shields of mated interface element ends ifpreferably selected such that very few things can get between the matedinterface ends to damage the contact displacement arrangement. The shapeof the various portions 50, 54 and 52 of the shield 12 facilitatesdefining a small slot with no other access space on either thenon-access side 30 or the access side 28.

FIG. 13C shows a front view of the main tap element 160 prior tooverlaying or molding on the tap body 140. As can be seen, connectionpoints 162 are provided for soldering on, welding or otherwiseconnecting lines of the tap cable 142. The tap element 160 is preferablymade in the form of a printed circuit board (PCB). The PCB 160 hastraces or other appropriate connection lines extending from contactpoints 162 to contacts 148.

The device is assembled by providing a cable at 22 as shown in FIG. 10aand placing twisted pair terminal ends 110 in the channels of the wireguide 64. As noted, the length of each terminal end 110 is the same. Thewire guide is placed into contact with the contact alignment body 14carrying contacts 62 and contact displacement device 66. Electricalcontact between the terminal ends 110 and the contacts 62 is preferablyprovided by ultrasonic welding. Other known connections may be providedsuch as displacement contacts soldering or other joining for electricalcontact. Ultrasonic welding is preferred as providing bettercharacteristics including no significant additional resistance.

A structure as shown in FIG. 5B results from the above steps.Subsequently, this structure is overlay molded to provide overlay moldedhousing 58. When this is provided on both ends of the cable, thisresults in a single contact displacement assembly 18 as shown in FIG. 4.The single CDA 18 has two interface ends. One end of contactdisplacement assembly 18 is inserted in a shield 12. The other end isinserted in another shield 12. Engagement bezel 113, at the base of eachcontact alignment body 14, facilitates the insertion of an interface endof assembly 18. Engagement protuberance 114 has a back edge whichprovides a locking function upon engagement with locking groove 57 ofshield 12 (see FIGS. 3B and 3C).

On the non-access side, by rails 60, a circuit indicator 20 may beconnected via rails 60 and the connection between groove 124 andprotuberance 134. In a similar manner, two color indicator labels canslide onto rails 60 on each side whereby locking protuberance 122 ofeach element 16 engages a respective locking groove 124 provided onrails 60. With these steps taken with regard to each interface element 8and 6, an assembly 10 as shown in FIG. 1 is provided. The interface endsof the CDA 10 are identical and each interface element of the assembly10 may mate with an identical interface element of another identicalassembly 10.

Matting of interface ends takes place with the tongue 34 being insertedbetween the lower surface of the top 26 of shield 12 and the uppersurface of male enclosure portion 38. Each male enclosure portion 38extends into each female enclosure portion 40 with the various portions52, 54 and 50 at the tap side engaging. When the engagement bezel 42 ispositioned such that the back edge engages the back edge of shield top26, the interface body of one assembly 10 is connected to the interfacebody of another assembly 10. In this position, the contacts 62 are in acontact position such that signals are transmitted downstream.

The tap 138 may be inserted on the tap side 28 of the shields of themated interface ends. The tap may be fixed via rail 60 and engagementpart 144. If the tap is inserted properly, engagement part 144 willconnect with rail 60 in the inserted position. This will break theelectrical contact between contacts 62 of two interfaces of twoassemblies 10. This will provide a tapping contact via the tap contacts148.

While specific embodiments of the invention have been shown anddescribed in detail to illustrate the application of the principles ofthe invention, it will be understood that the invention may be embodiedotherwise without departing from such principles.

What is claimed is:
 1. A telecommunications/data link and connectorinterface assembly, comprising: a transmission cable comprising aplurality of transmission lines; an interface end assembly connected tosaid transmission cable and including: a contact alignment bodyincluding a line connection end and an interface end, a plurality ofcontact elements being positioned and aligned by said contact alignmentbody and extending from adjacent to said line connection end toward saidinterface end, each of said contact elements being movable between acontact position and a non-contact position, each of said contactelements including a contact area and a line connection area for anelectrical connection with a line, and a housing, said contact alignmentbody being disposed in said housing in a locked position, said housingbeing substantially identical to a housing of another connectorinterface assembly and being matable therewith whereby contact elementscarried by said contact alignment body are in a contact position andcontact elements carried by a contact alignment body of said housing ofanother connector interface assembly are also in a contact positionproviding an electrical path through the connector to transmission linesof a downstream transmission cable; and a tap insertable between contactelements for tapping signals carried by said contact elements.
 2. Theassembly according to claim 1, further comprising: a contact openingdevice associated with said plurality of contact elements, said contactopening device including a tap engaging surface includingcamming/locking posts, said tap including a contact opening deviceengaging surface with post receiving openings, a tap transmission lineand contact portions, said contact opening device engaging surfacecooperating with said tap engaging surface camming/locking posts uponinsertion of said tap to urge said contact elements into a non contactposition and to move said contact element into a tapping position uponfurther insertion of said tap, said posts extending into correspondingsaid post receiving openings whereby said contact elements return to acontact position and said contact elements make electrical contact withsaid tap contact portions.
 3. The assembly according to claim 2, whereinsaid contact elements carried by said contact alignment body of saidhousing of said another connector interface assembly are associated withanother contact opening device including a tap engaging surfaceincluding camming/locking posts, said tap having a second contactopening device engaging surface without post receiving openings wherebyat least some of said contact elements carried by said contact alignmentbody of said housing of said another connector interface assembly areurged into a non contact position upon insertion of said tap, said tapincluding tapping contacts on one side only, whereby said contactelements carried by said contact alignment body of said housing of saidanother connector interface assembly are disconnected while said tap isin said tapping position to interrupt at least one said electrical paththrough the connector interface assembly to transmission lines of adownstream transmission cable.
 4. The assembly according to claim 1,wherein said housing of said connector interface assembly and saidhousing of said another connector interface assembly each include aplurality of male alignment tabs defining a space for receiving acontact alignment body and a plurality of female alignment tabs defininga space for receiving a contact alignment body, said male alignment tabsof one said housing being adapted for mating with said female alignmenttabs of another said housing and said housing each including a lockingmeans for locking said housings in a mated position.
 5. The assemblyaccording to claim 4, wherein said locking means includes a tongue and atongue receiving portion, said tongue including a locking bezel forlocking on back edge of said receiving portion.
 6. The assemblyaccording to claim 1, wherein said housing is an electromagnetic shieldformed of plastic with embedded metallic elements.
 7. The assemblyaccording to claim 1, further comprising an additional contact alignmentbody with contact elements, wherein said housing is provided forreceiving said additional contact alignment body, said housing definingan electromagnetic barrier for minimizing the effect of electromagneticfields generated by contacts of said contact alignment body on contactsassociated with said additional contact alignment body and forminimizing the effect of electromagnetic fields generated by contacts ofsaid additional contact alignment body on contacts associated with saidcontact alignment body.
 8. The assembly according to claim 1, furthercomprising: a wire guide; an overlay molded housing connected to saidtransmission cable, connected to said wire guide and connected to saidcontact alignment body to form a single contact displacement bodyinterface end with guide rails on each of two sides; an indicator labelelement adjacent to a first side of said housing; and another indicatorlabel element adjacent to another side of said housing, each indicatorlabel element including receiving grooves for receiving a plurality ofsaid support rails on one side to cooperate with a plurality of saidsingle contact displacement body interface ends and said housing to forma connector block.
 9. A telecommunications/data link and connectorsystem, comprising: a first transmission cable comprising a plurality oftransmission lines; a second transmission cable comprising a pluralityof transmission lines; a first interface assembly connected to saidfirst transmission cable and including: a first interface contactalignment body including a line connection end and an interface end,plurality of contact elements being positioned and aligned by said firstinterface contact alignment body and extending from adjacent to saidline connection end toward said interface end, each of said firstinterface contact elements being movable between a contact position anda non-contact position, each of said first side contact elementsincluding a contact area and a line connection area for an electricalconnection with a line, and a first interface housing, said firstinterface contact alignment body being disposed in said first interfacehousing in a locked position; a second interface assembly connected to asecond transmission cable and including: a second interface contactalignment body including a line connection end and an interface end, asecond interface plurality of contact elements each of said secondinterface plurality of contact elements being positioned and aligned bysaid second interface contact alignment body and extending from adjacentto said line connection end toward said second interface contactalignment body interface end, each of said second side contact elementsbeing movable between a contact position and a non-contact position,each of said second side contact elements including a contact area and aline connection area for an electrical connection with a line, and asecond interface housing, said second contact alignment body beingdisposed in said second interface housing in a locked position, each ofsaid first interface housing and said second interface housing eachinclude a plurality of male enclosures defining a space for receiving acontact alignment body, and including a plurality of female enclosuresdefining a space for receiving a contact alignment body, said maleenclosures of one housing being adapted for mating with said femaleenclosures of another housing and said housings each including a lockingmeans for locking to each other, wherein said locking means includes atongue and a tongue receiving portion, said tongue including a lockingbezel for locking on a back edge of a receiving portion of an identicalhousing.
 10. The assembly according to claim 9, wherein said firsthousing and second housing are shields to electromagnetic interferenceand are each formed of plastic with embedded metallic elements.
 11. Theassembly according to claim 10, wherein said first interface pluralityof contacts includes resilient means for supporting said contact areaallowing said contact area to move between said contact position andsaid non-contact position.
 12. The assembly according to claim 10,further comprising contact displacement means for moving contactsbetween said contact position and said non-contact position, and forallowing insertion of said tap between said first interface plurality ofcontacts and contacts of said substantially identicaltelecommunication/data link and connector assembly.
 13. The assemblyaccording to claim 12, wherein said contact displacement means includesa first contact opening device connected to said first interfaceplurality of contacts, said first contact opening device being engagedby said tap means, whereby said contact opening device moves contactsbetween said contact position and said non-contact position allowinginsertion of said tap between said first interface plurality of contactsand contacts of said substantially identical telecommunication/data linkand connector assembly.
 14. The assembly according to claim 13, whereinsaid contact displacement means includes a second contact opening deviceconnected to said second interface plurality of contacts, said secondcontact opening device moving said second interface plurality ofcontacts between said contact position and said non-contact positionupon engagement with a tip of said tap means.
 15. The assembly accordingto claim 9, wherein said first interface housing is provided forreceiving additional contact alignment bodies with associated contactsand said second interface is provided for receiving additional contactalignment bodies, whereby additional contacts of mated interfacehousings can be moved from a contact position to a non-contact position.16. An assembly according to claim 1, further comprising a wire guide,said transmission lines including twisted wire pairs with terminal ends,said wire guide having a wire entry side and a narrower width wireconnection side, said wire guide defining wire paths of substantiallyequal distance from said wire entry side to said wire connection side,said wire guide being disposed between said transmission cable and saidfirst contact alignment body.
 17. The assembly according to claim 16,further comprising an overlay molded housing connected to saidtransmission cable, connected to said wire guide and connected to saidfirst interface contact alignment body, said first interface contactalignment body including mold housing receiving sockets, said twistedpair terminal ends being electrically connected to said first interfaceplurality of contacts adjacent to said receiving sockets, a portion ofsaid first interface contact alignment body, said wire guide and aportion of said cable being disposed in a mold and material beinginjected therein to contact and surround said portion of said cable,said wire guide and said portion of said first interface contactalignment body forming a single contact displacement body interface. 18.The assembly according to claim 17, wherein said single contactdisplacement assembly interface includes a support rail, said tapincluding a support rail engaging means for engaging said support railwhen said tap is inserted between contact elements for tapping signalscarried by said contact elements.
 19. The assembly according to claim 9,wherein said first housing and second housing are shields toelectromagnetic interference and are each formed of plastic withembedded metallic elements.